Browse Topic: Braking systems

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Design-Driven Sustainability of Automotive Components: A Comparative LCA from Conventional to Metal and Composite Additive Manufacturing2026-37-0037To be published on 06/09/2026
The increasing pressure to decarbonize manufacturing systems is pushing industry beyond conventional lightweighting strategies toward material and process paradigms, capable of delivering functional performance with radically lower environmental impact. In this context, polymer-based composite Additive Manufacturing (AM) offers an underexplored yet highly promising pathway for sustainable production of load-bearing components. This study presents a preliminary comparative cradle-to-gate Life Cycle Assessment (LCA) of a Formula SAE brake pedal, assessing the environmental transition from conventional CNC machining of Aluminum 7075-T6 to additive manufacturing solutions, with specific focus on Carbon-Fiber-Reinforced Polymer (CFRP) composites. Two topology-optimized designs, respectively for Powder Bed Fusion (PBF) in AlSi10Mg and Material Extrusion (MEX) in PETG-CF are compared to machined aluminum benchmark. The analysis is integrated in the product and process design following ISO
Dalpadulo, Enrico, Russo, Mario, Apté MD, Raphaëlle, LEALI, FRANCESCO
Study of Approaches for Enhanced Traction Control Response for Hybrid Powertrain Architectures2026-01-0415To be published on 04/07/2026
Traction Control functionality requires fast and accurate response by powertrain system for wheel slip control. Close loop control effort of wheel slip shall be greatly reduced with more accurate feedforward torque. This paper explores the method of achieving requested traction control torque with better accuracy for torque converter-based hybrid electric powertrain architectures using improved dynamic modeling of torque converter. This method uses input inertia compensation involving feedforward and closed loop control modeling of torque converter and includes conversion of traction control intervention request through appropriate domains. Commanded torques by hybrid controller at wheel with and without these approaches are compared in Model in the loop simulation environment to identify optimum approach.
Karogal, Indrasen, Ober, Mitchell, Banuso, Abdulquadri, Sharma, Ashay
Research on Vehicle and Longitudinal Tire Model Parameters Identification Based on Electro-Mechanical Brake System2026-01-0634To be published on 04/07/2026
The Electro-Mechanical Brake (EMB) system is a novel type of brake by wire systems with independently controllable characteristics. This system aids in the decoupling analysis of the vehicle and actuator dynamics, thereby improving the accuracy of parameter identification. Therefore, this paper proposes an innovative parameter identification method for vehicle parameters and longitudinal tire model parameters, based on the characteristics of the EMB system and onboard sensors. First, based on the wind resistance and rolling resistance coefficients obtained from the vehicle coasting conditions, a decoupled constant clamping force sequence braking condition for the front and rear axles is designed by integrating the characteristics of the EMB actuator and vehicle dynamics. This approach enables the identification of vehicle and nonlinear longitudinal tire model parameters, significantly improving the accuracy of parameter identification. Next, considering the nonlinear characteristics of
Huang, Jiayi, Cheng, Yulin, Zhuo, Guirong, Le, Qiao, Wei, Wei, Shu, Qiang
An Adaptive Brake Force Allocation Strategy for Rear-Wheel Driven EVs2026-01-0636To be published on 04/07/2026
Due to changed requirements compared to conventional propulsion concepts, electromobility demands new and innovative strategies for energy-efficient vehicle motion control. For example, the challenge in purely rear-wheel drive (RWD) electric vehicles (EVs) is to achieve a maximum of regenerative braking power in order to increase energy recovery and to ensure, that this does not impair the braking stability. Within this conflict between energy efficiency and braking dynamics, it is necessary to design an intelligent strategy to optimise recuperation. This paper presents such a strategy, which improves an existing approach formerly presented by the authors, but specifically optimises it to overcome weaknesses. The previous approach had two major limitations: First, the efficiency map of the in-wheel machines (IWMs) was not considered. Second, there was no possibility of switching flexibly between different brake force distributions to guarantee both, maximized recovery potential and
Mitsching, Thomas, Heydrich, Marius, Ivanov, Valentin
Backlash Evasion Strategy for Enhancing Vehicle Cornering Performance2026-01-0640To be published on 04/07/2026
This study presents a torque distribution control strategy for EVs with e4WD powertrain to overcome the trade-off between ensuring vehicle acceleration and deceleration responsiveness and mitigating backlash shock in the driving system. The deterioration of the drivability which occurs from the intrinsic hardware characteristics of the drivetrain is prevented by designing a response-priority drive mode in which neither front or rear motor torque is allowed to change its sign. Instead, in such drive mode, the front motor torque is only allowed to perform regenerative braking while the rear motor torque is only allowed to produce positive acceleration torque. In order to avoid sacrificing the maximum acceleration by applying such strategy, the mode transition function is implemented as well. In addition, in order to prevent backlash impact due to drivetrain compliance, variable offset torque based on drivetrain compliance model is evaluated in real time and applied to each motor command
Oh, JIWON, Lee, Ho Wook
A Study of Federal Motor Vehicle Safety Standard 126 and 136 Test Procedures on a Class 5 Vehicle2026-01-0616To be published on 04/07/2026
Federal Motor Vehicle Safety Standards (FMVSS) 126 and 136 are standards imposed on four of the eight recognized road vehicle classes in The United States. These standards make it mandatory for Electronic Stability Control modules (ESC) to be mounted to Class 1,2,7, and 8 vehicles. These modules strategically activate the vehicle brakes via the Antilock Brake System (ABS) to limit the recorded yaw rate and lateral displacement of a vehicle during an extreme cornering maneuver such as a sudden swerve to avoid an obstacle on the road. The two aforementioned FMVSS mandates also specify three different driving maneuvers that are conducted to profile and analyze ESC module performance. There is now an interest in creating a new FMVSS that makes ESC modules mandatory for Class 5 vehicles. The purpose of this paper is to analyze how one specific Class 5 vehicle’s ESC module performed when subjected to the two test procedures that correspond to FMVSS 126 and 136. As will be seen, the vehicle’s
Cazares, Richard Isaac, Guenther, Dennis, Heydinger, Gary
Modular 3-D Lumped Parameter Thermal Network for Thermal Estimation of Permanent Magnet Synchronous Motors in Electro-Mechanical Braking Systems2026-01-0136To be published on 04/07/2026
With the development of electric intelligent vehicles, drive-by-wire systems are gradually popularized, the thermal reliability of electro-mechanical brake (EMB) motors, as the key actuators of drive-by-wire systems, is closely related to vehicle safety. However, the blocked-rotation operating condition of EMB motors typically involves applying unequal DC currents to the three-phase windings to achieve braking. This results in uneven winding heating, and conventional thermal models may fail to accurately represent the heat transfer dynamics arising from such tangential thermal imbalance, creating risks of motor local overheating. This paper is focused on thermal performance analysis of EMB motors under blocked-run conditions. First, a single-tooth lumped-parameter thermal network module (tooth module) incorporating external interfaces was developed. This module was adapted using experimental and simulation data, with its internal thermal parameters identified via a particle swarm
duan, yanlong, Xiong, Lu, Wang, Xinjian, Zhuo, Guirong, Zeng, Jie
Research on electro-hydraulic compound braking coordinated control strategy based on sliding mode control2026-01-0631To be published on 04/07/2026
Hydraulic braking torque and motor braking torque are the main sources of braking torque of new energy vehicles. Hydraulic braking converts vehicle kinetic energy into heat dissipation, and motor braking converts vehicle kinetic energy into electric energy to achieve energy recovery. In the process of vehicle braking, when the wheels tend to lock, it is easy to cause vehicle instability, which seriously threatens the safety of driving.Therefore, how to coordinated the braking torque of the two braking systems to ensure the vehicle braking safety and energy recovery efficiency is still an urgent problem to be solved. In this paper, the electric vehicle equipped with electro-hydraulic compound braking system is taken as the research object, and the electro-hydraulic compound braking coordinated control strategy considering the general braking state and emergency braking state is proposed. Firstly, a 3-DOF vehicle longitudinal dynamic model is established according to the vehicle dynamic
Zhao, Gaoming, Zhao, Bingquan, Zhao, Binggen, He, Chengkun, Zhang, Xiaoyang
Vehicle Health Monitoring and Failure Prognosis through Edge-Based Component Wear Tracking2026-01-0094To be published on 04/07/2026
Traditional vehicle maintenance has relied primarily on mileage-based schedules and periodic visual inspections, approaches that often fail to account for variations in driving conditions, component quality, and usage patterns. These conventional methods typically result in either unnecessary premature replacements or unexpected component failures, leading to increased operating costs and unplanned downtime. Reactive maintenance strategies prove particularly problematic for critical wear components like clutch assemblies, brake systems, and suspension parts where undetected degradation can cause secondary damage. This paper presents an advanced monitoring system that shifts from scheduled maintenance to actual condition-based servicing through real-time wear measurement. The solution implements a network of distributed sensors that directly track critical parameters: ultrasonic measurement of clutch plate thickness, resistive wear sensors for brake pads, linear potentiometers for
Saraswat, Shubham, Vishe, Prashant
Characterizing Regenerative Braking of Tesla Model 3 Using Dynamometer Testing2026-01-0453To be published on 04/07/2026
Regenerative braking has a strong influence on the energy efficiency and drivability of battery-electric vehicles. This study establishes an empirical baseline analysis under controlled conditions of the regenerative braking behavior of the 2020 Tesla Model 3 to support the interpretation of on-road performance and serve as a reference for subsequent testing and analysis. The tests were performed on a four-wheel-drive chassis dynamometer at Argonne National Laboratory, combining Multi Cycle Testing (MCT) to simulate real world driving patterns (city, highway) with coast-down tests to isolate periods where the motor is operating in regen mode and compare the behavior across different parameters. Vehicle data was collected from the vehicle using taps in the Controller Area Network (CAN) bus as well as a high-resolution power analyzer. The vehicle displayed the highest efficiency during simulated city driving conditions (3.62 miles/kWh followed by highway (3.40 miles/kWh) and aggressive
Pierce, Benjamin Branch, Di Russo, Miriam, Das, DEBASHIS, Zhan, Lu
Prediction of Pressure Pulsation in Brake Line Considering Wave Propagation Characteristics of Fluid Contained in Flexible Hose for Automotive Hydraulic Brake System2026-01-0225To be published on 04/07/2026
Brake pulsation noise caused by fluid-borne vibration, which is generated by pressure pulsations from the pump in the Electronic Stability Control (ESC) modulator, occurs when the control brake function is activated under various driving conditions, such as Adaptive Cruise Control (ACC) and regenerative-friction brake coordination. This noise is particularly noticeable in Battery Electric Vehicles (BEVs), where the background noise from the power source is lower than that of internal combustion engine vehicles. The simulation of pressure pulsations in the brake system requires the excitation force of the pump built into the ESC modulator, the characteristics of valves, and the characteristics of the flexible hose; however, it is extremely difficult to determine these parameters with high accuracy from the design specifications. For this reason, in this study, the pump and valves were experimentally identified, while the flexible hose was represented by a three-element Voigt model to
Koike, Yohei, Komada, Masashi, Yano, Masahiro, Yoshioka, Nobuhiko
Development of a lightweight and quick-to-install pedal robot for unmanned chassis dynamometer testing2026-01-0197To be published on 04/07/2026
As electric vehicles become more popular, their development and testing using chassis dynamometers is also increasing. Compared to internal combustion engine vehicles, chassis dynamometer testing for electric vehicles requires several to dozens of times longer, requiring increasingly more labor. Furthermore, low-temperature testing is also required, further increasing the labor intensity of testing. Therefore, we developed and evaluated a pedal robot to facilitate unmanned and automated testing. The pedal robot developed in this study weighs only 12 kg and can be installed in a matter of minutes. It is the world's first pedal robot that mimics human driving behavior by driving with one foot and operating the accelerator and brake pedals. Unlike existing driving robots, the robot's actuators do not need to be directly connected to the vehicle pedals, making installation quick. Furthermore, it is installed on the floor of the driver's seat, eliminating the need for a seat attachment. The
Lee, Daeyup, Kang, ji myeong, Jo, Yechan, Choi, SeongUn, shin, Jaesik, Kim, Jongmin, Kang, Keonwoo, Lee, Jongtae
Machine Learning for Predicting Rotor and Brake Fluid Temperatures in Hill Descent Events2026-01-0159To be published on 04/07/2026
High thermal loads on brake systems during extended descents followed by vehicle soak pose significant safety and durability risks. Excessive rotor or fluid temperatures can cause loss of braking efficacy, fluid degradation or evaporation, thermal fade, and accelerated component wear. This study uses time history data of brake disc and fluid temperatures collected during controlled hill descent events and subsequent soak (park) periods, and simultaneously logs environmental conditions (ambient temperature, humidity, wind speed and direction) and brake specifications (rotor, caliper geometry, pad material, fluid type, and vehicle mass). Seventy six test runs from a dedicated validation program are used, each providing time history records that form the basis of our analysis. From these records we extract phase specific samples (descent and soak phase) and engineer compact descriptors, such as start and peak temperatures, environmental factors, rolling statistics and contextual metadata
poojari, Uday Kumar, Westphalen, Jan, Venugopal, Narayana
Inertial Pedal Displacement and Brake Switch Activation in Frontal Crash Events2026-01-0541To be published on 04/07/2026
This paper presents research into the inertial displacement of brake pedals and the subsequent activation of brake light switches during crash events. In certain scenarios—such as multiple-impact crashes or with pre-impact interactions such as curb strikes or sideswipes—inertial forces alone may generate sufficient brake pedal movement to trigger the brake switch, activating the brake lights. Such signals may be recorded by an Event Data Recorder (EDR) or observed by witnesses and mistakenly interpreted as an indication of intentional driver braking. To investigate this phenomenon, HYGE sled tests were performed using brake pedal assemblies and associated components from a Toyota Tacoma pickup truck and a Cadillac DeVille passenger sedan. The assemblies were subjected to acceleration pulses simulating a frontal impact, with high-speed video used to capture brake pedal displacement and brake light activation. The tests demonstrated that inertial loading from a pulse with a delta-V
Duran, Amanda, Walker, James, Barnes, Daniel, Osterhout, Aaron, Clayton, Aidan
The Effect of Tread Depth on Antilock-Brake System (ABS)-Equipped Decelerations for Dry and Wet Asphalt and Concrete Road Surfaces2026-01-0549To be published on 04/07/2026
The effect of tire tread depth on the performance of anti-lock brake systems (ABS) in newer vehicles is not well studied. A single ABS-equipped SUV was used to perform a series of 216 ABS-engaged braking tests on dry and wet asphalt and concrete surfaces using uniform sets of tires with tread depths varying from 0.8 mm (1/32”) to 7.1 mm (9/32”). Vehicle speed and deceleration as a function of time were calculated from 5th-wheel data sampled at 200 Hz. Tests were initially conducted on a dry surface, with tire sets changed between tests. A water truck then distributed water onto the road to create a wet condition and additional tests of each tire set were conducted. Deceleration levels did not change significantly from 7.1 mm (9/32”) down to 2.4 mm (3/32”) of remaining tread on both surfaces in both conditions. Compared to the deceleration levels at these larger tread depths, dry deceleration levels increased for tread depths of about 0.8 mm (1/32”) and 1.8 mm (2/32”) on both asphalt
Miller, Ian, King, David, Siegmund, Gunter P.
Vehicle Deceleration Levels during Wet-to-Dry Transitions on an Asphalt Surface with a High Proportion of Aggregate2026-01-0542To be published on 04/07/2026
The goal of this study is to quantify how the braking performance of newer anti-lock braking systems (ABS) changes as the level of road wetness varies on an asphalt road surface with a high proportion of aggregate present in the asphalt matrix. To achieve this goal, we conducted 375 straight-line braking tests using a late-model sedan and SUV on a public road in Mississauga, ON. Each vehicle was equipped with a 5th wheel (resolution 0.1 mm) sampled at 200 Hz, from which vehicle speed and deceleration were calculated. The road surface was wetted four times and allowed to dry each time under ambient conditions over a period of about one hour. As the road transitioned from wet to dry, a continuous series of ABS-braking tests were performed from an initial speed of 60 km/h. Both the maximum and average decelerations for each braking event were compared between six “wetness” categories assigned to the road surface condition present for each test. We found that the vehicles were able to
Ahrens, Matthew, Arnold, Nikolas, Miller, Ian, Siegmund, Gunter P.
Two-Channel Pressure Control Using an Electric Cylinder and a Solenoid Valve for Electronically Controlled Brake Systems2026-01-0638To be published on 04/07/2026
With the rapid proliferation of electrified vehicles (xEVs), maximizing regenerative energy recovery has become a crucial challenge in realizing zero-emission mobility. In front-wheel-drive (FWD) vehicles, regenerative braking acts only on the front axle, resulting in a braking-force distribution biased toward the front. When uniform hydraulic pressure is applied to both axles, excessive braking force on the front wheels may cause premature wheel lock and hinder the intended regenerative braking effect. To address this issue, it is essential to implement an independent pressure control strategy (two-channel pressure control) that appropriately reduces front pressure according to regenerative force while independently maintaining adequate rear pressure. This study proposes a new two-channel pressure control architecture utilizing a simple and reasonable actuator set consisting of one electric cylinder and one solenoid valve. The electric cylinder generates hydraulic pressure by
Kaneko, Shosuke, Deno, Yoshitomo, Kobayashi, Tatsushi, Kawamura, Hikaru
Embedded Real-Time Control of a Distributed Trailer Propulsion System with Regenerative Braking for Net Neutral Load Towing2026-01-0065To be published on 04/07/2026
Towing significantly degrades vehicle efficiency, reducing battery-electric vehicle (BEV) range by up to 50% and increasing internal-combustion engine (ICE) fuel consumption by ~30%. To address this challenge, this paper presents a real-time embedded control architecture for a distributed trailer propulsion system that actively regulates drawbar force to achieve net neutral load towing while enabling regenerative braking. Unlike prior e-trailer concepts, this platform demonstrates a cost-effective, fully networked, model-based control implementation using commercial off-the-shelf components. The control system integrates dual Raspberry Pi controllers running ROS 2: one samples a hitch-mounted load cell at 100 Hz and the other processes OBD-II/CAN messages. Controllers designed in MATLAB/Simulink are deployed to a 5 kWh LiFePO₄ pack and a 5 kW traction motor, utilising embedded Linux for real-time scheduling and onboard data logging. Two operating modes are implemented: (i) PI
Joshi, Gaurav, Adelman, Ian, Liu, Jun, Donnaway, Ruthie
Quantifying the Impact of Towing on BEV Energy Use: Instrumented On Road Testing and Chassis Dynamometer Reproduction2026-01-0431To be published on 04/07/2026
Electrification is rapidly entering all vehicle classes, including light- and heavy-duty trucks designed for heavy towing capabilities. Still, the quantitative impact of towing on battery-electric vehicle (BEV) energy use and range remains under-characterized. We conducted controlled towing tests with a Ford F-150 Lightning using two trailers of different sizes and varying payloads to isolate aerodynamic and mass effects across the vehicle’s rated towing capacity. The vehicle was instrumented at the CAN bus level to capture motor power, torque, speed, and other related internal signals. On-road testing consisted of repeated back-and-forth passes on level, straight road segments at set speeds focusing on highway operation, where aerodynamic drag is stronger and real-world towing use cases occur. From these data, we extracted road load equations and dynamometer coefficients for each trailer combination, then reproduced equivalent conditions on a four-wheel drive chassis dynamometer
Timermans Ladero, Inigo
Heavy Vehicle Controls Prioritization and Conflict ResolutionJ3081_202603 (Current)3/25/2026
This document is written to address acceleration and deceleration control issues related to heavy-duty trucks and buses greater than 10000 GVW.
Truck and Bus Brake Systems Committee
Air Brake Actuator Test Procedure, Truck-Tractor, Bus, and TrailersJ1469_202603 (Current)3/13/2026
This SAE Recommended Practice provides procedures and methods for testing service, spring applied parking, and combination brake actuators with respect to durability, function, and environmental performance. A minimum of six test units designated A, B, C, D, E, and F are to be used to perform all tests per 1.1 and 1.2.
Truck and Bus Brake Actuator Committee
Quasi-Static Mechanical and Dynamic Flow Model of Brake Vacuum Booster Using Hybrid Methodology2026-01-50193/11/2026
This study primarily focuses on quasi-static mechanical modeling and dynamic flow modeling of the brake vacuum booster used in a typical four-wheeled passenger vehicles, under brake apply condition. Vacuum Booster is a key component of brake actuation system whose primary function is to multiply the force received from brake pedal. A hybrid methodology consisting of FEA and 1D simulation of the vacuum booster has been constructed in this study by accommodating its compliance. The brake vacuum booster consists of two chambers, namely vacuum and apply chamber; the force multiplication in vacuum booster occurs because of pressure difference between these two chambers. The hybrid methodology not only captures its flow dynamics but also accommodates the structural interaction that happens between the ratio disc (rigid body) and the reaction disc (hyperelastic body) with the help of finite element analysis, which is the novel part of this project. The result from finite element analysis is
Iyengar, Sharan Yoganand, Mani Saravanan, C., Gopalan, Seshadri
Accuracy Requirements for the Road Friction Coefficient Estimation of a Friction-Adaptive Automatic Emergency Braking System as a Software Solution for Integrated Chassis Control Systems10-10-02-00163/10/2026
As part of this work, the accuracy requirements for the road friction coefficient estimation of a friction-adaptive automatic emergency braking (AEB) system are determined using a complex, nonlinear vehicle model. The AEB system varies its trigger distance depending on an estimated value of the road friction coefficient. The accuracy requirements are determined at a driving speed of 40 km/h depending on the severity classification of ISO 26262 in the statistically relevant Euro NCAP test scenario with a stationary target vehicle. MATLAB/Simulink is used as simulation software. The permissible estimation error (difference between estimated value and road friction coefficient) is determined by the severity classification S1 (light and moderate injuries). The results show that the positive permissible estimation error (road friction coefficient is overestimated) must not exceed about 30% of the road friction coefficient to comply with the severity classification S1 of ISO 26262.
Ahrenhold, Tim, Wielitzka, Mark, Binnewies, Tomas, Henze, Roman
Human-Like Automatic Braking Algorithm Based on Kinematic Cue: Yield Behavior Analysis and Fuzzy Controller Design10-10-03-00192/25/2026
Pedestrians are among the most vulnerable participants in traffic, particularly when crossing the road. Extensive research has been conducted globally on the yielding behavior analysis of vehicle–pedestrian interaction and the design of automatic vehicle braking systems to mitigate pedestrian casualties. However, few studies have comprehensively addressed lateral risks using implicit kinematic cues in pedestrian–vehicle interactions. Moreover, the design of collision avoidance systems has rarely taken into account driving behavior, along with the pedestrian’s kinematics and crossing behavior. This article presents a human-like automatic braking fuzzy control strategy for pedestrian–vehicle collision avoidance, combining the advantages of professional driver emergency braking behavior and kinematic interaction cues. First, a high-fidelity driving simulator is used to investigate the yielding behavior of pedestrian–vehicle interaction when pedestrians cross the road. Second, the
Zhang, Wenyan, Huang, Xiaorong, Sun, Shulei, Fu, Kairong, Xiong, Qing, Huang, Haibo
Yaw Coordinated Control Based on Fuzzy Control and Stability Region Theory10-10-03-00182/23/2026
Electric vehicle chassis integration control aims to improve vehicle handling and comfort. Previous studies encountered significant practical limitations, such as computational overhead in real-time execution scenarios. Designing effective and efficient algorithms for actuator coordination remains challenging. This article presents a synergetic controller for chassis coordination, combining fuzzy logic and stability region theory. First, the controller targets are the yaw rate and side slip angle, which are obtained from a highly accurate multi-body dynamic model. In addition, based on the generated fuzzy rules, the system calculates the required additional yaw moments for each actuator and optimizes their output. Then, the designed controller can distribute control effort optimally in real-time between braking and rear-wheel steering based on the stability status of the vehicle. Furthermore, a stability factor approach is used to formulate a dynamic safety strategy executed by the
Liao, Yinsheng, Hu, Zhiming, Cheng, Yuanshu, Lin, Ruya, Sun, Yue, Gao, Sixiao, Zhang, Junzhi
Sensitivity Analysis toward Differential Braking as Backup Steering Functionality2026-01-50132/20/2026
This paper presents a novel sensitivity analysis framework for differential braking as a backup steering solution in fail-operational Steer-by-Wire systems. The fault-tolerant design approach of Steer-by-Wire and steering systems for highly automated driving relies on the availability of road wheel actuators (RWA). Redundancies are therefore commonly used to ensure fail-operationality. Since its widespread implementation in production vehicles through electronic stability control, the use of differential braking as a cost-effective measure is desirable to increase functional diversity. However, feasible lateral accelerations through this backup solution are limited compared to conventional steering systems and lie close to ordinary driving scenarios. To address this limitation, this work investigates the influence of chassis parameters on differential braking performance. After defining characteristic values and a simulation test plan, a preliminary analysis using a linear single-track
Salzwedel, Leon, Iatropoulos, Jannes, Heise, Cedric, Frohn, Christian, Henze, Roman
Brake Pads, Lining, Disc, and Drum Wear MeasurementsJ2986_202602 (Current)2/19/2026
This SAE Recommended Practice provides a common method to measure wear of friction materials (brake pad assemblies and brake shoes) and their mating parts (brake disc or brake drum). These wear measurements apply to brakes fitted on passenger cars and light trucks up to 4536 kg of Gross Vehicle Weight Rating under the Federal Motor Vehicle Safety Standard (FMVSS), or vehicles category M1 (passenger cars up to nine occupants, including the driver) under the European Community’s ECE Regulations.
Brake Dynamometer Standards Committee
Four-Wheel Independent Steering Vehicle Control under Wheel-Corner Brake Faults10-10-04-00282/18/2026
Wheel-corner brake failures can significantly deteriorate vehicle stability and safety, since unbalanced braking forces may introduce an undesired yaw moment. This work investigates a fault-tolerant control strategy for Active Wheel-Corner Systems, exploiting Four-Wheel Independent Steering (4WIS) to mitigate such effects and preserve vehicle stability when brake actuator malfunctions occur. Unlike many existing approaches, the proposed framework does not require explicit fault detection or quantification as a prerequisite for corrective action, eliminating potential delays and uncertainties associated with fault-diagnosis schemes. A reference model for yaw rate and sideslip angle, incorporating combined longitudinal and lateral dynamics, is proposed, and a Weighted Pseudo-Inverse Control Allocation (WPCA) scheme is employed to distribute corrective actions among the four steering angles according to each tire’s capability, compensating for yaw moment imbalances caused by degraded
Sonnino, Samuel, Melzi, Stefano, Caresia, Pietro, Manzoni, Alessandro, Vaini, Gianluca
Inertia-Dynamometer Disc Brake Drag Measurement Test Procedure for Vehicles Less Than 4540 kg GVWRJ2923_202602 (Current)2/12/2026
The SAE J2923 procedure is a recommended practice that applies to on-road vehicles with a GVWR below 4540 kg equipped with disc brakes.
Brake Dynamometer Standards Committee
Design and Development of Integrated Brake and Bull Cage System for Enhanced Tractor Performance and Sustainability2026-28-00052/12/2026
Conventional tractor transmission systems feature separate Brake and Bull Cage housings, with brakes often being proprietary components and Bull Cage designed by the Original Equipment manufacturer (OE). To optimize design and performance, an innovative integrated system was developed, combining an in-house braking system with a unitized Bull Cage assembly. This robust design reduces part count, eliminates proprietary dependency (except for friction liners), and enhances performance. Virtual simulations performed under RWUP conditions demonstrated enhanced strength and stiffness in the integrated design. In this Integrated Brake & Bull Cage assembly (IBCA), the braking layout was reconfigured from a 4+1 friction design to a 3+2 configuration which improved balancing, enhancing customer braking experience and increasing contact area by 11%. This adjustment extends friction liner life and boosts mechanical advantage by 7.9%, significantly improving tractor stability and performance
Dumpa, Mahendra Reddy, Dhanale, Swapnil, Perumal, Solairaj, Gomes, Maxson, Redkar, Dinesh, Savant, Kedarnath, V, Saravanan
Structural Redesign and Functional Integration of an Electrohydraulic Brake Valve for Enhanced Performance and Manufacturability2026-28-00022/12/2026
The Electrohydraulic Brake Valve (EBV) is a vital component in full-power brake systems for heavy-duty and off-highway vehicles, providing precise hydraulic pressure modulation through electrical control. Traditionally, EBV housings are manufactured using bar-machined components, which offer durability but contribute significantly to the overall weight and cost of the assembly. In response to increasing demands for lightweight and cost-effective solutions, this study presents a targeted design optimization of the EBV housing. The redesigned housing adopts a casting-based geometry, integrates sensor ports for pressure monitoring, and includes a nameplate mounting provision for customer identification. Material substitution and structural simplification were employed to enhance manufacturability and performance. Finite Element Analysis (FEA) was used to validate the mechanical integrity of the new design under operational conditions. The optimized EBV assembly achieved a weight reduction
R, Thangarajan
Real time Implementation of Predictive Maintenance for Service Center Automation Using Automobile Life Extender (ALE) Based on Machine Learning2026-28-01242/12/2026
The Automobile Life Extender (ALE) comprises an on-board function, a machine learning model operating via cloud computing and a smartphone app. The on-board function receives signals such as engine RPM, throttle position, brake pedal position, and hydraulic pressure from the vehicle's ECUs. Based on this data, the on-board ALE module calculates the engine load, brake circuit load, etc., and sends it to the predictive maintenance model via the on-board IoT system. The predictive maintenance model contains recorded data about the type of engine, brake system, and their performance curves acquired from tests conducted by its OEM. Machine learning models holds a crucial role in dynamically analyzing vehicle data, identifying drive patterns, and predicting the need for maintenance of a part or system. A hybrid approach of training models based on supervised and unsupervised learning is incorporated, creating an active learning strategy to maximize the use of available data. Amazon SageMaker
Sundaram, Rameshselvakumar, Kumar, Lokesh, Saint Peter Thomas, Edwin, Sureshkumar, Srihari, Muthukumaran, Chockalingam, Menon, Abhijith
Vibrational Analysis of Hybrid Composite Laminated Plates of E – Glass and Areca Fibers with Brake Pad Waste Powder2026-28-00732/12/2026
This study focuses on the vibration analysis of hybrid composite laminated plates fabricated from E-glass Fiber and areca Fiber reinforced with epoxy resin. The hybrid laminates were prepared using the Vacuum Assisted Resin Transfer Moulding (VARTM) process with different stacking sequences and Fiber ratios, where brake lining powder was also incorporated as a filler in selected configurations to enhance mechanical and damping properties. The fabricated plates (280 × 280 mm) were subjected to experimental modal analysis using an impact hammer and accelerometer setup, with data acquisition carried out through DEWESoft software. Natural frequencies and damping ratios were determined under three boundary conditions (C- C-C-C, C-F-C-F, and C-F-F-F). The results revealed that Plate 1, with E-glass outer layers, areca reinforcement, and filler addition, exhibited the best vibration performance, achieving a maximum natural frequency of 332.8 Hz under C-C-C-C condition, while Plate 2 showed a
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, R G, Ajay Krishna, Ng, Bhavan
Benchmark of Conventional and By-Wire Brake System Layouts for Electric Vehicle Applications by Numerical Simulations2026-01-50082/3/2026
The recently increasing global concern about sustainability and greenhouse gas emission reduction has boosted the diffusion of electric vehicles. Research on this topic mainly focuses on either re-designing or adapting most conventional vehicle subsystems, especially the propulsion motor and the braking components. In this context, the present work aims to model, analyze, and compare three-braking system layouts design alternatives focusing on their contribution to vehicle performance and efficiency: a commercial vacuum-boosted hydraulic braking system, a commercial integrated electrohydraulic braking system, and a concept distributed electrohydraulic brake system. Braking systems performance are evaluated by simulating key maneuvers adopting a full model of a battery electric vehicle (BEV), which includes all relevant components like tires, and powertrain dynamics, which is validated against real-world data. Implementation and integration of the first two systems are discussed
Savi, Lorenzo, Garosio, Damiano, Floros, Dimosthenis, Vignati, Michele, Travagliati, Alessandro, Braghin, Francesco
Niobium Alloyed Brake Disc for reduced NVH and Emission Control2026-26-02851/16/2026
Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technologies to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium and subsequently Ferritic Nitrocarburize (FNC) the disc. The Niobium addition will improve the wear resistance of the FNC case, reducing wear debris. The test methodology included: 1. Manufacture of disc samples alloyed with Niobium, 2. Finish machining and ferritic nitrocarburizing and 3. Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3
Barile, Bernardo, Holly, Mike
Scalable and Modular Data-Driven Hybrid Chassis Dynamometer Framework for EV Powertrain Evaluation2026-26-03631/16/2026
In its conventional form, dynamometers typically provide a fixed architecture for measuring torque, speed, and power, with their scope primarily centered on these parameters and only limited emphasis on capturing aggregated real-time performance factors such as battery load and energy flow across the diverse range of emerging electric vehicle (EV) powertrain architectures. The objective of this work is to develop a valid, appropriate, scalable modular test framework that combines a real-time virtual twin of a compact physical dynamometer with world leading real-time mechanical and energy parameters/attributes useful for its virtual validation, as well as the evaluation of other unknown parameters that respectively span iterations of hybrid and electric vehicle configurations, ultimately allowing the assessment of multiple chassis without having to modify the physical testing facility's test bench. This integration enables a blended approach, using a live data source for now, providing
Kumar, Akhilesh, V, Yashvati
Enhancing Range Prediction Accuracy for the BEV: Bridging the Gap between Simulation and Real-World Testing2026-26-05211/16/2026
Accurate range estimation in battery electric vehicles (BEVs) is essential for optimizing performance, energy efficiency, and customer expectations. This study investigates the discrepancies between physical test data and simulation predictions for the BEV model. A detailed range delta analysis identifies key contributors to the observed deviations, including regenerative braking inefficiencies, increased propulsion demand, auxiliary loads, and estimated drivetrain losses within the Electric Drive Module (EDM) during traction and regen. Results indicate that the test vehicle exhibits lower regenerative braking efficiency, higher traction forces and lower regen energy than predicted by simulations, primarily due to EDM inefficiencies and friction brake usage during regeneration. The study underscores the importance of refining simulation methodologies by integrating real-world, test based EDM loss maps to improve accuracy and better align predictive models with actual vehicle
Mahajan, Prasad, Kesarkar, Sidhesh, Ali, Shoaib
Predictive SoC Management for Enhanced Recuperation Efficiency in Electric Vehicles2026-26-01541/16/2026
In recent years, the automotive industry has been looking into alternatives for conventional vehicles to promote a sustainable transportation future having a lesser carbon footprint. Electric Vehicles (EV) are a promising choice as they produce zero tail pipe emissions. However, even with the demand for EVs increasing, the charging infrastructure is still a concern, which leads to range anxiety. This necessitates the judicious use of battery charge and reduce the energy wastage occurring at any point. In EVs, regenerative braking is an additional option which helps in recuperating the battery energy during vehicle deceleration. The amount of energy recuperated mainly depends on the current State of Charge (SoC) of the battery and the battery temperature. Typically, the amount of recuperable energy reduces as the current SoC moves closer to 100%. Once this limit is reached, the excess energy available for recuperation is discharged through the brake resistor/pads. This paper proposes a
Barik, Madhusmita, S, Sethuraman, Aruljothi, Sathishkumar
Brake Emission Testbed Automation and Control: Insights and New Developments2026-26-02321/16/2026
A significant contributor to particle mass (PM) emissions originating from road transport are particles emitted from brakes, which in Europe are considered in the upcoming Euro 7 emission legislation. UN-GTR (United Nations Global Technical Regulation) no. 24 describes the methodology for measuring brake particle emissions in a test cell setting with a dynamometer, both in terms of PM and PN (particle number). A regulation-compliant test fulfills various quality criteria for different control parameters, which can often be met by applying different control strategies. In this study, we evaluate the effects of implementing different control strategies for torque applied to the brake by the dynamometer, as well as for sampling flow. Additionally, we discuss the cost-saving potential of increasing the automation degree of testing, as well as modifying existing testbeds to accommodate brake emission testing. The torque control strategies applied in this study did not influence PN or PM
Martikainen, Sampsa, Weidinger, Christoph, Huber, Michael Peter
Simulation of EV Range Estimation for Different Payload of Vehicle2026-26-03891/16/2026
The electrification of transportation is revolutionizing the automotive and logistics sectors, with electric vehicles (EVs) assuming an increasingly pivotal role in both passenger mobility and commercial activities. As the adoption of EVs rises, the necessity for precise range estimation becomes essential, especially under diverse operational circumstances, including vehicle and battery characteristics, driving conditions, environmental influences, vehicle configurations, and user-specific behaviors. Among the varying factors, a key fluctuating one is user behavior—most notably, increased payload, which significantly affects EV range. A key business challenge lies in the significant variability of EV range due to changes in vehicle load, which can affect performance, operational efficiency, and cost-effectiveness—especially for fleet-based services. This research aims to tackle the technical deficiency in forecasting electric vehicle (EV) range under various payload conditions
Khatal, Swaraj, Gupta, Anjali, Krishna, Thallapaka
Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer2026-26-05111/16/2026
Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking
M, Vipin Prakash, Rajappan, Dinesh Kumar, R, Suresh, N, Gopi Kannan
A Novel Analytical Approach to Predict Passenger Vehicle Parking Brake Cable Performance2026-26-04831/16/2026
The performance of passenger vehicle parking brake cables is critical for ensuring vehicle safety and functionality. Vehicle manufacturer evaluates the robustness of cable performance at different road gradient conditions. Effort and stroke performance are among the key parameters for evaluating cable performance. While parking brake system should be designed to minimize effort losses through the cable routing, packaging constraints often prevent it. Excessive losses within the parking brake system, particularly in cable force transmission, can lead to insufficient braking force and may cause vehicle slippage when parked on an inclined surface or non-level terrain. Therefore, it is essential to estimate the losses through cable routing and optimize parameters of the parking brake cable system. Currently, the methods used for evaluating cable performance are either experimental or empirical based. CAE methods using finite element analysis (FEA) and multibody dynamic approaches are
Iqbal, Shoaib, Sabri, Salah, Siddiqui, Arshad
Smart Stability: Automation of Braking Solutions, Hill Hold and Parking Brake Strategy in Tractors Using Electro-Hydraulic Actuation2026-26-02051/16/2026
Agricultural operations in hilly, uneven & slopy terrains demands high levels of operator focus, effort and skill. However, todays farming ecosystem across the globe is affected by 2 major scenarios: the aging workforce in the agricultural sector and the ever-growing problem of distraction due to mobile device and social media use. These issues compromise safety during operations such as start stop maneuvers, parking on slopes, and maneuvering in confined & narrow areas. Stringent emission norms are also being mandated across developed and developing countries as a measure to reduce Global Greenhouse house gas emissions. These measures are indeed necessary for sustainability but has increased overall tractor purchase and operating costs without improving safety & operator comfort. There has been a trend seen around the world in terms of poor sales post Emission implementation. Registration of Older tractors without these stringent emission norms were also witnessed in Developed
M, Rojer, T, Ganesan, P, Velusamy, Natarajan, Saravanan, V, Mathankumar, tripathi, Shankar, Narni, Kiran, Haldorai, Rajan, Devakumar, Kiran
Self-Supervised Diagnostics & Prognostics Framework for Predictive Maintenance in Electric Vehicles2026-26-06731/16/2026
Predictive maintenance is critical to improving reliability, safety and operational efficiency of connected vehicles. However, classic supervised learning methods for fault prediction rely heavily on large-scale labeled data of failures, which are difficult to obtain and maintain a manually built dataset of failure events in real automotives settings. In this paper, we present a novel self-supervised anomaly detection model that makes predictions on the faults without the need for labeled failures by using only the operational data when the systems or robots are healthy. The method relies on self-supervised pretext tasks, like masked signal reconstruction and future telemetry prediction, to extract nominal multi-sensor dynamics (i.e., temperature, pressure, current, vibration) while jointly minimizing the deviation between encoded/decoded signals and normal patterns in the latent space. A unsupervised anomaly detection model is then used to detect when the learned patterns are violated
Kumar, Pankaj, Deole, Kaushik, Hivarkar, Umesh
Simulation Research on Torque Vectoring, Braking, Chassis Control Strategies for Electric & Hybrid Vehicles using System Simulation2026-26-04231/16/2026
Electric Vehicles and Plug-in Hybrids alleviate the energy crisis but pose a unique challenge for vehicle dynamics. Though significant developments in motor control strategy and energy density management are evolving, we face significant challenges in torque management, with several ADAS features being an integral part of the EVs/xHEVs. It demands high-fidelity physical and control model exchanges between electric chassis, ride-handling, tire modelling, steering assist, powertrain, and validation using a 0D–1D platform. This paper explicates a unified strategy for improving overall vehicle performance by intelligently distributing and coordinating drive torque to enhance traction, stability, and drivability across diverse operating conditions through co-simulation. The co-simulation platform includes physical models in AMESIM, and control strategies integrated in MATLAB/Simulink. The platform features comprehensive representations of digital vehicles that require detailed modelling of
Eruva, Patrickxavier, Sarapalli Ramachandran, Raghuveeran, Chougule, Sourabh, Natanamani-Pillai, Siva Subramanian, Scheider, Clement, Leclerc, Cedric, Natarajasundaram, Balasubramanian
Evaluation of Thermo-Mechanical Behavior of Brake Discs in Vehicles Using Multidisciplinary Approach2026-26-04331/16/2026
The objective of this paper is to evaluate the thermal performance of the brake discs in the design stage of its life cycle by developing a methodology to replicate dynamometer testing using multi-disciplinary Finite Element Analysis (FEA) methods. A simulation workflow was formulated in which Computational Fluid Dynamics (CFD) was used to create temperature and velocity dependent Heat Transfer Coefficients (HTC) which were in turn used in Computer Aided Engineering (CAE) to do a thermo-mechanical analysis. With this workflow various designs of the brake discs were analyzed. A sensitivity study was done to determine critical design features that affected its thermal performance. A final design was fixed that met both the weight and thermal performance targets. This design was evaluated in dynamometer testing, and 93% correlation was achieved. Thus, the developed simulation workflow ensured that a first-time right brake disc can be finalized in the design stage, which will meet the
Balaji, Praveen, K, Karthikeyan, S, Kesavprasad, S Kangde, Suhas, Reddy, Jagadeeswara
Design Optimization of the Propeller Shaft and Transfer Case for High-Speed 4WD Vehicles2026-26-03431/16/2026
Nowadays, vehicle enthusiasts often vary the driving patterns, from high-speed driving to off-roading. This leads to a continuous increase in demand for four-wheel drive (4WD) vehicles. A 4WD vehicle have better traction control with enhanced stability. The performance and reliability of 4WD vehicles at high speeds are significantly influenced by driveline stiffness and natural frequency, which are largely affected by the propeller shaft and transfer case. This study focuses on the design optimization of the transfer case and the propeller shafts to enhance the vehicle performance at high speeds. The analysis begins with a comprehensive study of factors affecting the power transfer path, transfer case stiffness, and critical frequency, including material properties, propeller shaft geometry, and different boundary conditions. Advanced computational methods are employed to model the dynamic behavior of the powertrain, identifying the natural frequency of the transfer case and propeller
Kumar, Sarvesh, Yadav, Sahdev, S, Manickaraja, Sanjay, L, Kanagaraj, Pothiraj, Jain, Saurabh Kumar, Deole, Subodh M
Auto Braking System for Preventing Commercial Vehicle Overloading2026-26-00321/16/2026
Overloading in vehicles, particularly trucks and city buses, poses a critical challenge in India, contributing to increased traffic accidents, economic losses, and infrastructural damage. This issue stems from excessive loads that compromise vehicle stability, reduce braking efficiency, accelerate tire wear, and heighten the risk of catastrophic failures. To address this, we propose an intelligent overloading control and warning system that integrates load-sensing technology with real-time corrective measures. The system employs precision load sensors (e.g., air below deflection monitoring via pressure sensors) to measure vehicle weight dynamically. When the load exceeds predefined thresholds, the system triggers a multi-stage response: 1 Visual/Audio Warning – Alerts the driver to take corrective action. 2 Braking Intervention – If ignored, the braking applied, immobilizing the vehicle until the load is reduced. Experimental validation involved ten iterative tests to map deflection-to
Raj, Amritesh, Pujari, Sachin, Londhe, Mahesh, Shirke, Sumeet, Shinde, Akshay
Systemic Modelling and Simulation Approach to Estimate Brake Response Time in a Pneumatic Brake Systems2026-26-04691/16/2026
Brake response time in truck air brake systems is crucial for ensuring safety and operational efficiency. This paper details the development of a simulation model aimed at fulfilling all regulatory requirements for brake response time, as well as serving as a tool for stopping distance calculations. The actual pneumatic circuit, including brake valves, relay valves, brake chambers, and plumbing have been replicated. The aim is to use 1D simulations to predict the response time compliance during the pressurizing phase (when brakes are applied) of the brake system. A mathematical model is developed using a commercially available 1D simulation tool. This model employs a lumped parameter approach for the pneumatic components, with governing equations derived from compressible flow theory and empirical valve flow characteristics. The simulation outcomes provide detailed response time and pressure build-up profiles. Validation against 201 vehicle test cases showed 96% of simulations within
Kumbar, Praful, Murugesan, Karthik, Shannon, Rick
A Complex Road Surface Parameter Estimation Method Based on the Fusion Framework of Visual Classifier and Dynamics Observer10-10-02-00131/16/2026
Special vehicles such as off-road vehicles and planetary rovers frequently operate on complex, unpaved road surfaces with varying mechanical parameters. Inaccurate estimation of these parameters can cause subsidence or rollover. Existing methods either lack proactive perception or high precision. This article proposes a fusion framework integrating a visual classifier and a dynamics observer for stable, accurate estimation of road surface parameters. The visual classifier uses an adaptive segmentation system for unpaved roads, leveraging a large-scale vision model and a lightweight network to classify upcoming road surfaces. The dynamics observer employs an online wheel-–ground interaction model using stress approximation, integrating strong tracking theory into an unscented Kalman filter for real-time parameter estimation. The fusion framework performs integration of the classifier and observer outputs at data, feature, and decision levels. An adaptive fading factor and recursive
Zhang, Chenhao, Xia, Guang, Zhang, Yang, Zhou, Dayang, Shi, Qin
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